Integrated vehicle-end structure

ABSTRACT

An integrated end structure for a vehicle comprises: a storage compartment module that comprises a shell forming a storage compartment therein, the storage compartment module configured to sit onto a frame rail of the vehicle; and a vehicle end module configured to be mounted onto a bracket in the vehicle that provides adjustability of the vehicle end module in a z-direction, the vehicle end module configured for holding a light unit of the vehicle. The storage compartment module is mounted onto the vehicle end module.

BACKGROUND

Vehicle assembly in manufacturing plants is a complex operation thatinvolves many thousands of components that must be brought together in aspecific order to effectively, yet precisely and accurately, producemany vehicles of a given type. The quality of the resulting vehicle isprimarily judged in terms of its safety and suitability for its intendedpurpose. However, other characteristics are also considered, such as thefit between body panels, whether decorative elements are level, whetherthe headlights or taillights are properly aligned or askew, and otherelements of visual appearance. These and other aspects are sometimesreferred to as the craftsmanship of the vehicle.

SUMMARY

In a first aspect, an integrated end structure for a vehicle comprises:a storage compartment module that comprises a shell forming a storagecompartment therein, the storage compartment module configured to sitonto a frame rail of the vehicle; and a vehicle end module configured tobe mounted onto a bracket in the vehicle that provides adjustability ofthe vehicle end module in a z-direction, the vehicle end moduleconfigured for holding a light unit of the vehicle; wherein the storagecompartment module is mounted onto the vehicle end module.

Implementations can include any or all of the following features. Theintegrated end structure is an integrated front end structure, andwherein the light unit is a front headlamp. The vehicle end modulecomprises a left headlamp bracket mounted on one side of a centermodule, and a right headlamp bracket mounted on an opposite side of thecenter module. The vehicle end module further comprises an attachmentfor a hood latch of the vehicle. The storage compartment module and thevehicle end module are made from at least two different composites. Thevehicle end module is at least partly hollow and the storage compartmentextends into the vehicle end module. The bracket is part of a bumperbeam attachment in the vehicle.

In a second aspect, an integrated end structure for a vehicle comprises:a storage compartment module that comprises a shell forming a storagecompartment therein, the storage compartment module configured to sitonto a frame rail of the vehicle; and means for i) taking load carryingcapability from the storage compartment module, ii) holding a light unitof the vehicle, and iii) setting at least an x-direction position of theintegrated end structure, the means configured to be mounted onto abracket in the vehicle that provides adjustability of the means in az-direction; wherein the storage compartment module is mounted onto themeans.

In a third aspect, a method comprises: placing a center module for anintegrated end structure for a vehicle in a fixture separate from thevehicle; attaching at least one side bracket to the center module in thefixture to form an assembly, the side bracket configured for holding alight unit of the vehicle; mounting the assembly onto at least a bracketin the vehicle that provides adjustability of the assembly in az-direction; and after mounting the assembly, mounting a storagecompartment module onto the center module and the side bracket.

Implementations can include any or all of the following features.Placing the center module and attaching the side bracket take placeoffline an assembly line, the method further comprising bringing theassembly to the assembly line, wherein mounting the assembly andmounting the storage compartment module take place on the assembly line.Mounting the assembly onto the bracket comprises picking up the assemblyusing at least x-direction datums on the center module. Placing thecenter module comprises setting at least an x-direction position for theintegrated end structure. Attaching the side bracket comprises settingat least an x-direction position for the side bracket. The methodfurther comprises adjusting the side bracket relative to the centermodule in at least an x-direction to adjust a position of the lightunit. The method further comprises attaching the light unit to the sidebracket before mounting the storage compartment module. The methodfurther comprises attaching fascia to the assembly before mounting thestorage compartment module. Mounting the storage compartment modulecomprises attaching the storage compartment module by a fastener to aflange of the center module that sets at least an x-direction positionof the integrated end structure. The method further comprises adjustingat least a z-direction position of the integrated end structure bychanging a z-direction position of the bracket.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows an example of a front end module.

FIG. 2 shows an example of the headlamp brackets attached to a trunk.

FIG. 3 shows an example of an integrated vehicle end structure.

FIG. 4 shows an example of an extended storage compartment area.

FIG. 5 shows an example of the integrated vehicle end structure mountedonto bumper beam attachments.

FIG. 6 shows an example of headlight assemblies mounted onto theintegrated vehicle end structure.

FIG. 7 shows an example of attachment points for the trunk.

FIG. 8 shows a cross section of the center module and the trunk.

FIG. 9 shows an example of a manufacturing process for an integratedvehicle end structure.

DETAILED DESCRIPTION

This document describes examples of systems and techniques for providingan integrated end structure in a vehicle. Such a structure can allowindividual components to share load carrying capability with each other.As another example, it can provide flexibility in adjusting the positionof the end structure during assembly, or in particular, flexibility inadjusting the position of vital exterior-facing components (e.g.,headlights). In some implementations, the integrated end structure ismade from one or more vehicle end modules that form an arcuate shape soas to allow a voluminous component (e.g., a trunk) to later be mountedinside the arced space and thereby complete the entire assembly at thatend of the vehicle. For example, this can provide a structuralload-sharing assembly at the vehicle end. The vehicle end module can bemade from respective components that are precision fitted together toensure the positioning of components attached to the vehicle end module.

A vehicle front end is described as an illustrative example. However,the term vehicle end is used broadly herein so as to include both thefront end and the rear end of a vehicle. Also, some of the examplesmention a trunk, and it is contemplated that the vehicle can have atrunk in the front and/or the rear. Finally, the present descriptionmakes no particular assumption of where the vehicle's motor(s)—such aselectric or combustion motor(s)—should be located. The vehicle can havea single motor located in the rear, or a single motor located in thefront, or at least two separate motors, to name just some examples.

FIG. 1 shows an example of a front end module 100. The module here ismade up of three separate parts: a center module 102 and respective sidebrackets 104A-B. In other implementations, the front end module 100 canbe a single component.

The center module is here adapted to be placed centrally at the vehiclefront end and be mounted onto a bracket that provides up/downadjustability of the front end module, such as a bumper beam attachmentof the vehicle. The side brackets can be adapted for holding vehicleheadlamp assemblies or other light units and for being attached to atleast the center module and the bracket. For example, fasteners (notshown) attach these components to each other at locations 106.

Other aspects of the figure will be described below with regard to anassembly process.

FIG. 2 shows an example of the headlamp brackets attached to a trunk200. This view that omits the center module 102 (FIG. 1) is provided forillustrative purposes. Namely, in some implementations, the sidebrackets are attached to the center module before the trunk is mountedonto that assembly. In other words, this view does not necessarily showthe assembly as it appears during any stage of a manufacturing process.Nevertheless, the current view shows how the side brackets can bepositioned adjacent the trunk, and also that the trunk can have anopening 202. For example, when the center module is at least partiallyhollow, the opening can provide additional storage space for the trunk.That is, the trunk is here a separate module that is in a sense shapedlike a tub; for example, the trunk can be made from a shell 204 of anysuitable shape that is formed so as to create a storage compartment 206therein. A trunk is not the only type of structure contemplated,however; another type of storage compartment module for a vehicle can beused.

The trunk and the vehicle end module (e.g., the side brackets and centermodule) can be made from a suitable material. In some implementations,one or more types of composite materials can be used. For example, theside brackets and/or the trunk can be made of polypropylene, optionallywith a reinforcing material such as glass fiber. As another example, thecenter module can be made of a thermosetting material, optionally with areinforcing material such as glass fiber. In implementations where theend module is a single component, it can be made of (optionallyreinforced) polypropylene or a thermosetting material, to name just twoexamples.

FIG. 3 shows an example of an integrated vehicle end structure 300.Here, the integrated vehicle end structure is an integrated vehiclefront end that includes the center module 102, the side brackets 104A-Band the trunk 200. That is, these components are here shown attached toeach other to form an entire assembly. In some implementations, thestructure 300 is not built separately but rather is formed when therespective elements are mounted onto a vehicle frame during themanufacturing process.

The integrated nature of the assembly can provide useful advantages. Insome implementations, bolting (or otherwise fastening) these four piecestogether can create a strong structure at the vehicle end. For example,this assembly can define the complete structure of the vehicle at thatend in a way that load paths exist through all the components. Each ofthe components can take load carrying capability from each of the otherones. For example, the center module can take load carrying capabilityfrom the trunk module. As another example, the load carrying capabilityof the trunk can be improved by some or all of the other pieces. In someimplementations, the integrated vehicle end reduces mass of the vehiclestructure compared to other approaches.

FIG. 4 shows an example of an extended storage compartment area 400.This example shows part of the inside of the trunk 200, wherein the area400 is formed inside the center module 102, which here is hollow,attached to the trunk. For example, the area 400 adds volume of storagespace to the trunk beyond its original size, and can accommodate itemsthat would otherwise be too long to fit inside. That is, the storagecompartment of the trunk here extends into the center module.

This illustration also shows that the center module 102 can be used toattach other structure 402. For example, fascia for the front (or rear)of the vehicle and/or other components can hang from the center module.This can provide advantages from the points of view of craftsmanship andmanufacturing flexibility, as will be described later.

FIG. 5 shows an example of the integrated vehicle end structure 300mounted onto bumper beam attachments 500. Here, the bumper beamattachments serve as the point of attachment to the vehicle for a bumperbeam 502. This creates a z-datum for the vehicle end structure so thatits position in an up/down direction can be controlled. For example,this can achieve fore/aft slip to accommodate build variation and floatof the vehicle end structure and the truck, while allowing the vehicleend to be built according to nominal specifications. In otherimplementations, the vehicle end structure 300 can be mounted ontoanother bracket that provides adjustability in an up/down direction.

In this example, crush cans 504 connect the bumper beam to therespective bumper beam attachment. That is, the bumper beam attachmentconnects the bumper beam to the vehicle frame (here located rearward ofthe bumper beam attachments) to absorb crash loads in an accident.

In some implementations, each bumper beam attachment has a flange 506 atits upper end on which the center module 102 and/or the side brackets104A-B can be mounted. For example, the flange can provide anessentially horizontal surface. Each of the side brackets can be mountedonto the bumper beam attachment using two bolts 508 or any other type offastener; the center module can be mounted using one or more fasteners(not shown) on each of its sides.

The side brackets 104A-B can attach to the vehicle body in one or moreother areas. In some implementations, such attachment(s) can bepositioned further inward on the vehicle (here, further back). Forexample, at least one attachment point 510 can be used where a part ofthe vehicle body (not shown) comes forth. That is, all components of theintegrated vehicle end structure 300 rest on top of the bumper beamattachment. This too can provide advantages from the points of view ofcraftsmanship and manufacturing flexibility.

As a particular example, the hood of a vehicle must usually attach to astructural vehicle member to ensure that it does not inadvertentlybecome unlatched. For instance, the load requirement for the hood latchcan be several thousand Newton. The hood latch assembly therefore drivessignificant structural requirements for the vehicle end assembly. Here,the center member 102 can serve as an attachment for a hood latch (notshown) to provide such a structural member for the hood. For example,one or more attachment points 512 on the center module can be used formounting the hood latch.

Because the vehicle end module is attached to the trunk, it can betterwithstand forces applied to the hood. That is, assuming that the trunkis a very rigid part relatively speaking, this arrangement helps shed aportion of the hood latch load into it, for example in the event of acrash. The load is also transferred into the bumper beam attachment orother bracket where the vehicle end module is mounted. The structuralassembly formed by the vehicle end module and the trunk can also provideother advantages, such as improved NVH (noise, vibration, harshness)characteristics for headlamp units.

The side brackets 104A-B in turn, can attach to the trunk 200 in one ormore places. For example, one or more attachment points 514 on each sideof the trunk can be used for that respective side bracket. In someimplementations, the side bracket is configured to have a lamp assembly(e.g., for headlights or taillights) mounted on it. For example, one ormore attachment points 516 on each bracket can be used by the respectiveheadlamp. The lamp assembly can also or instead be attached to the trunkin one or more places. For example, one or more attachment points 518 oneach side of the trunk can be used by a headlamp on that respectiveside.

FIG. 6 shows an example of headlight assemblies 600 mounted onto theintegrated vehicle end structure 300. That is, each headlamp assembly isattached to a respective one of the side brackets 104A-B. For example,lamp assemblies (whether front or rear) can be significant for vehicleappearance and it can therefore be important to ensure that they arepositioned correctly. Examples described herein of integrated modularstructures holding such lamp assemblies provide useful flexibility andconvenience when installing headlamps (or other components) duringmanufacture.

FIG. 7 shows an example of attachment points for the trunk 200. Thetrunk module sits on top of the vehicle body. In some implementations,the vehicle frame includes frame rails 700 underneath the trunk. Forexample, the bumper beam attachments (not shown) can be mounted at theend of each such respective frame rail. Attachment points 702 at thebottom of the trunk can be the only attachment between the trunk and therespective rails.

The center module 102, moreover, can attach to the trunk in one or moreplaces. In some implementations, the attachments can be made through theside wall and/or a bottom of the trunk. For example, six attachmentpoints 704 can be used.

FIG. 8 shows a cross section of the center module 102 and the trunk 200.The center module has a recessed portion 802 that meets with a wall 804of the trunk. In some implementations, the wall 804 is on the portion ofthe trunk that faces the vehicle end (here, forward in the vehicle). Forexample, the wall 804 can be part of structure that defines the opening400 in the trunk.

One or more attachment points 806 between the center module and thetrunk can be defined. In some implementations, attachment point(s) canbe above an opening between these components. On the center module, theattachment(s) can be located on a flange that serves to correctlyposition the trunk in one or more directions based on the positioning ofthe center module.

FIG. 9 shows an example of a manufacturing process 900 for an integratedvehicle end structure. The method will be illustrated with reference toexamples described herein where the end structure is made from separatemodules; however, some parts of the method can also or instead beperformed with other structures, such as a non-modular vehicle endstructure. Some aspects of FIG. 1 will also be referenced in thefollowing.

At 902, a center member is brought into a fixture. In someimplementations, this takes place on the side of a manufacturing linewhere vehicles are being made. That is, some of the steps in the methodcan be performed “on the bench” in that the fixture is situated at aseparate location from the vehicle where the assembled components are tobe installed. For example, the fixture can be a structure havingprecisely defined datum points at certain spatial locations relative toeach other so as to allow an exact assemblage of modular components intoone integrated unit that meets dimensional requirements specific to thevehicle. The center module can be clamped into the fixture at one ormore suitable positions of the module. For example, the module can beclamped to the fixture approximately at position 930.

At 904, the center module is datumed in x-, y- and z-directions fromcertain locations on the fixture. Directions can be defined relative tothe vehicle body in any suitable way. As used herein (see, e.g., FIG.1), an x-direction corresponds to the fore/aft position relative to thevehicle, a y-direction corresponds to a cross-vehicle position, and az-direction corresponds to an up/down position. Accordingly, anyposition relative to the vehicle being assembled can be specified usingparticular (x,y,z) coordinates. With this center module, for example,the x-direction—that is, how much fore or aft of a predefined referencepoint the module is located—is being controlled on the fixture. Forexample, the clamping can ensure that the module is correctly positionedin the x-, y- and z-directions.

Any suitable locations on the center module can be used for datuming themodule. In some implementations, positions both toward the top andtoward the bottom of the module can be used. For example, points 932 ona flange of the center module can be used. One or more of the datumingpoints can be chosen based on an intended point of attachment or contactbetween the center module and another component (e.g., the trunk).

At 906, the side brackets are brought into the fixture. The sidebrackets can be datumed in one or more directions using the fixture. Insome implementations, the side bracket is datumed only at one or morelocations that serve as attachment points for an external component(e.g., a light unit). For example, at 908 the side brackets can bedatumed in the x-, y- and z-directions using points 934 on eachrespective side bracket. At 910, the members are attached together, andcan then be assembled together with one or more ancillary components.

The fixture allows the datum points of the side bracket—which in thisexample are the headlamp attachment points that require carefulpositioning in the vehicle assembly—to be exactly placed relative to theflange of the center module. This approach provides a way to accommodatesize variations resulting from when these components were made, such asby a molding process, by only setting the mounting points for theimportant component, in this case the headlamp. In other words,craftsmanship depends on how the headlamp fits in the vehicle relativeto its fender, to the fascia and to the hood, to name some examples, andthe use of an integrated vehicle end structure built of modular partsallows attachment points for significant components to be positioned(e.g., in the x-direction) relative to a common reference. That is, herethe attachment points 934 for the headlamp become accurately set in atleast the x-direction relative to the flange of the center component102. The side brackets and the center module are attached to each otherusing any kind of fastener, such as several bolts on each side.

At 912, the assembly is picked up from the fixture. In someimplementations, an assembly aide picks up the assembly using some orall of the datum points. For example, the topmost two of the points 932can be used. This can ensure that the correct positioning (e.g., in thefore/aft direction) will be preserved. At 914, the assembly is broughtto the vehicle being built. In implementations where the vehicle endmodule is a single piece, operations 902 through 910 can be omitted.

At 916, the assembly is set in at least one direction relative to avehicle component. For example, using the datum points 932 of the centermodule, by which the assembly was picked up, the assembly can be set atits intended position relative to a fender of the vehicle. That is, whenthe assembly is correctly set in at least the x-direction by way of theflange of the center module, then the significant attachment points(here, the headlamp attachment) are also correctly x-positioned as aresult. This correlation follows from the spatial relationship betweenthese components that was defined using the fixture.

While another component (e.g., the fender) can be used as a referencepoint for setting the center module in the x- and/or y-direction, thecenter module and the respective side brackets will all rest on thebumper beam attachments. These have already been attached to the framerail in a precise position. For example, the bumper beam attachment canbe set in the z-direction relative to a specified position on thevehicle body. That is, the bumper beam attachment (and therefore thebumper beam itself) is therefore correctly positioned in the up/downdirection. Moreover, because the bumper beam attachments will carry theintegrated vehicle end structure, the entire vehicle end will have thecommon z position. Stated somewhat differently, during the assemblyprocess the entire vehicle end structure can effectively be floatedfore/aft or left/right or both to ensure the best fit. The modularstructure also has advantages for future repairs, because instead ofhaving to strip down the whole end of the car, one can simply replaceany of the trunk, center module, or the side brackets as needed.

At 918, the headlamps are mounted on the side members. For example, thisis done using the attachment points on the side brackets that wereprecisely datumed based on the x-position of the center module.

At 920, one or more other components are mounted on the vehicle. In someimplementations the component(s) can be mounted on some part of theintegrated vehicle end structure. For example, fascia can be attached tothe center module and/or to the side brackets. This allows the fascia toshare the same x- and/or y-position as the center module and the othercomponents of the integrated vehicle end.

At 922, the trunk is inserted in the position defined by the centermodule and the side brackets. In a sense, the trunk is the piece thatties together all parts of the vehicle end structure. In someimplementations, the trunk assembly takes place toward the end of theassembly line, significantly later than when the front end module (e.g.,the center module 102 and the side brackets 104A-B) were installed. Forexample, this provides access to areas underneath the trunk space duringthe manufacturing process. The trunk and the center module are attachedto each other at 924. For example, this can allow the flange of thecenter module to correctly position the trunk in the x- and/ory-direction.

Other components are mounted to the trunk at 926. For example, the trunkmodule can serve as the attachment structure for an underhood apronsystem.

The operations exemplified above can be performed as part of a standardmanufacturing process for each individual vehicle. Some implementationsdescribed herein, moreover, provide useful flexibility when it comes toupdating the manufacturing process itself. Such actions are hereexemplified in operations 928 and 930, which are enclosed by a dashedline to indicate this distinction. At 928, it is schematically indicatedthat the height of the bumper beam can be changed. Because the entirevehicle end assembly sits on the bumper beam attachments, its height(here the z-position) can be adjust by changing the height of theseattachments. In particular, the fit of fascia can be affected by raisingor lowering the bumper beam attachment. In a sense, the integratedvehicle end structure and its being mounted onto the bumper beamattachments can be said to create a z-plane in which to flexibly setimportant vehicle components to their proper position. That is, if onefinds that the vehicle is building with a slight gap in a particularplace, the whole assembly can be brought up or down, of fore/aft, or theindividual headlamp brackets can be shifted independently.

As another example, one may find that one side of a type of vehicle isbuilding somewhat longer or shorter than the other side. This can becompensated for by collecting data about the variation and applying thatin a “mean shift” adjustment of the fixture. Subsequent vehicles willthen be built with the relevant components in a modified positionrelative to each other. This is schematically indicated at 930.

Two or more of the operations of the method 900 can occur in a differentorder. As another example, more or fewer operations can be performed.

A number of implementations have been described as examples.Nevertheless, other implementations are covered by the following claims.

What is claimed is:
 1. An integrated end structure for a vehicle, theintegrated end structure comprising: a storage compartment module thatcomprises a shell forming a storage compartment therein, the storagecompartment module configured to sit onto a frame rail of the vehicle;and a vehicle end module configured to be mounted onto a bracket in thevehicle that provides adjustability of the vehicle end module in atleast a z-direction, the vehicle end module configured for holding alight unit of the vehicle; wherein the storage compartment module ismounted onto the vehicle end module.
 2. The integrated end structure ofclaim 1, wherein the integrated end structure is an integrated front endstructure, and wherein the light unit is a front headlamp.
 3. Theintegrated end structure of claim 1, wherein the vehicle end modulecomprises a left headlamp bracket mounted on one side of a centermodule, and a right headlamp bracket mounted on an opposite side of thecenter module.
 4. The integrated end structure of claim 1, wherein thevehicle end module further comprises an attachment for a hood latch ofthe vehicle.
 5. The integrated end structure of claim 1, wherein thestorage compartment module and the vehicle end module are made from atleast two different composites.
 6. The integrated end structure of claim1, wherein the vehicle end module is at least partly hollow and thestorage compartment extends into the vehicle end module.
 7. Theintegrated end structure of claim 1, wherein the bracket is part of abumper beam attachment in the vehicle.
 8. An integrated end structurefor a vehicle, the integrated end structure comprising: a storagecompartment module that comprises a shell forming a storage compartmenttherein, the storage compartment module configured to sit onto a framerail of the vehicle; and means for i) taking load carrying capabilityfrom the storage compartment module, ii) holding a light unit of thevehicle, and iii) setting at least an x-direction position of theintegrated end structure, the means configured to be mounted onto abracket in the vehicle that provides adjustability of the means in atleast a z-direction; wherein the storage compartment module is mountedonto the means.